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WO1998006112A1 - Transformateur planaire - Google Patents

Transformateur planaire Download PDF

Info

Publication number
WO1998006112A1
WO1998006112A1 PCT/US1997/013752 US9713752W WO9806112A1 WO 1998006112 A1 WO1998006112 A1 WO 1998006112A1 US 9713752 W US9713752 W US 9713752W WO 9806112 A1 WO9806112 A1 WO 9806112A1
Authority
WO
WIPO (PCT)
Prior art keywords
winding
metal strip
windings
insulative
strip conductor
Prior art date
Application number
PCT/US1997/013752
Other languages
English (en)
Inventor
Paul E. Grandmont
Qun Lu
Fei Ma
Original Assignee
International Power Devices, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by International Power Devices, Inc. filed Critical International Power Devices, Inc.
Priority to EP97938117A priority Critical patent/EP0919062A4/fr
Publication of WO1998006112A1 publication Critical patent/WO1998006112A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2804—Printed windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type
    • H01F17/0006—Printed inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/041—Printed circuit coils

Definitions

  • the invention relates to high power planar transformers.
  • Magnetic transformer and inductor components are an important class of components used in these power supplies and are generally the most difficult to miniaturize.
  • so called “planar magnetic components” e.g., transformers and inductors
  • PCB printed circuit board
  • a planar winding assembly includes first and second windings, each winding having an axis and a pair of insulative sheet layers which are laminated together, with at least one of each of the pairs of insulative sheets having a hole.
  • Each winding further includes a metal strip conductor that is wound about the axis of its winding and is sealed between the laminated insulative sheet layers.
  • the metal strip conductor has a portion projecting into the hole.
  • the metal strip conductor of the first winding is electrically interconnected (e.g., soldered) to the metal strip conductor of the second winding through the holes of the insulative sheets.
  • This invention provides a relatively small, low- profile transformer capable of handling high power (e.g., greater than 150 watts) and having a high isolation voltage (e.g., greater than 6,000 volts). Moreover, the transformer is highly reliable and can be operated over a wide temperature range.
  • Embodiments of the invention may include one or more of the following features.
  • the first winding is a multiple turn winding.
  • the first and second windings are adhesively bonded together.
  • Each of the metal strip conductors may be formed on a lead frame element.
  • the insulative sheet members are polyimide and the metal strip conductors are copper.
  • the planar winding assembly further includes a third winding disposed between the first and second windings and having a metal strip conductor.
  • the first and second windings are interconnected to provide a primary of a planar transformer with the third winding providing a secondary of the transformer.
  • at least one of each of the pairs of insulative sheets of each of the first, second and third windings includes a hole.
  • the holes formed in the first and second windings exposes a portion of the metal strip conductor associated with the insulator sheet having the hole so that the electrical connection of the metal strip conductors can be made through the holes of the first, second and third windings.
  • the first, second and third windings are adhesively bonded together.
  • the holes provide a convenient way of electrically interconnecting the first and second windings which are generally multiple-turn planar windings and have been individually sealed between laminated insulative sheets.
  • the first and second windings may form a primary winding of a transformer with the third winding being a secondary winding symmetrically positioned between each half of the primary.
  • the third winding is not electrically interconnected to either the first or second winding.
  • the hole formed in the third winding allows the first and second windings to be electrically interconnected therethrough.
  • the relatively thick metal strip conductors are laminated between a pair of relatively thin insulative sheets windings to ensure high voltage isolation between the windings as well as a highly reliable seal even when the windings are operated at high temperatures (e.g., as high as 120°C) .
  • the assemblies e.g. , circuit boards
  • the windings are individually-sealed to ensure that they are moisture impervious during such cleaning procedures.
  • the windings can be fabricated and sealed in a highly repeatable manufacturing process. Individually sealing each winding also allows the windings to be combined to provide a wide variety of transformers or other magnetic coil component configurations. That is, a large number of transformers or magnetic coil components may be constructed from a limited number of winding configurations simply by stacking and interconnecting the windings in different ways. Moreover, because the windings are individually sealed, the adhesive used in bonding the windings together need not be relied upon to provide a moisture impervious seal of the windings.
  • the transformer embodiment may further include a ferrite core member with the insulative sheet members of the first and second windings having an aperture sized to receive the ferrite core member.
  • FIG. 1 is a perspective view of a planar transformer of the invention.
  • Fig. 2 is an exploded view of the planar transformer of Fig. 1.
  • Fig. 3 is a cross-sectional side view of the transformer along lines 3-3 of Fig. 1.
  • Figs. 4A-4C are plan views of the winding elements of the planar transformer of Fig. 1.
  • Fig. 5 is a flow diagram illustrating an approach for fabricating the planar transformer of Fig. 1.
  • Fig. 6A and 6B are cross-sectional side views of a portion of the transformer of Fig.l, prior to and after bending of the tab ends of the metal strips, respectively.
  • Fig. 7 is a cross-sectional side view of a portion of an alternate embodiment of the transformer of Fig.l after bending of the tab ends of the metal strips.
  • Fig. 8A and 8B are plan views of the winding elements of Fig. 7.
  • Fig. 9 is a cross-sectional side view of an alternate embodiment of a transformer.
  • Fig. 10 is a plan view of a winding element of the transformer of Fig. 9.
  • transformer 10 capable of handling 150 watts while providing isolation voltages greater than 6,000 volts is shown. Moreover, transformer 10 has a relatively small overall outer dimension. In particular, the transformer has a lead-to-lead length of approximately 1.25 inches, a width of 0.75 inches and a depth of 0.30 inches. Transformer 10 includes a primary winding consisting of a pair of winding elements 12, 14 and a secondary winding 16 positioned therebetween. Winding elements 12, 14, 16 include flat metal strips 12a, 14a, 16a, respectively, each formed of rigid conductive metal, preferably, copper or copper alloy.
  • the metal strips have a substantially 5 rectangular cross section and a thickness between about 0.010 and 0.040 inches.
  • the metal strips have a multi- turn configuration in which a series of straight segments wind inwardly about an axis 20 of the winding elements.
  • Metal strip 12a winds inwardly clockwise from a terminal
  • metal strip 14a which is a mirror image of metal strip 12a — winds inwardly counterclockwise from a terminal 31 at an outer edge of winding 14 to an inner tab 30 (Fig. 4C) .
  • Metal strips 12a, 14a, 16a are individually encapsulated between a pair of insulative sheets 22 having a thickness between about 0.0005 and 0.001 inches.
  • a polyimide film having a thermally bondable 0 acrylic adhesive coating is used to insulate the metal strips.
  • Pyralux®, Kapton® polyimide film, a product of E.I Dupont de Nemours & Co., Wilmington, DE, is particularly well suited for encapsulating the metal strips to ensure a moisture impervious seal.
  • insulative sheets 22 include pre-formed holes 24 for allowing the winding elements 12, 14 to be electrically interconnected. Note that although the winding elements 12, 14, 16 are shown to be relatively thin in Fig. 2, in 0 reality, they are much thicker as more accurately depicted in the cross-sectional views of Figs. 3 and 6A.
  • Metal strips 12a and 14a provide a multi-turn winding, each having, in this embodiment, two turns so that when the metal strips are connected together, a four 5 turn-primary winding is provided.
  • Metal strip 16a of secondary winding 16 has only a single turn extending between terminals 32 positioned at an edge of the winding.
  • the assembled transformer of Fig. l has a 4:1 turns ratio.
  • a nominal 48 volt input which is supplied at terminals 26, 31 provides a highly- regulated 12 volt output (30 Amperes) at terminals 32 of secondary winding 16.
  • Primary current introduced at terminal 26 of metal strip 12a, flows through metal strip 12a and to metal strip 14a via the interconnection of inner tabs 28, 30 of the metal strips. The primary current continues to flow through metal strip 14a to a terminal 31.
  • the primary current flowing through windings 12 and 14 generates a magnetic field which is coupled to secondary winding element 16 to produce the stepped-up (or stepped- down) voltage at terminals 32.
  • terminals 26, 31, 32 are bent to allow attachment to surface mounted holes of a printed circuit board.
  • the winding elements 12 , 14 , 16 are mounted within a transformer core assembly 34 having an E-core member 36 and a top plate 38 both of which are formed of a sintered ferrite material, and together provide a flux path for the magnetic field generated by the winding elements.
  • E- core member includes a center post 40 and a pair of end posts 42 which together define a pair of channels 44 within which the winding elements are positioned.
  • the insulative sheets 22 of winding elements 12, 14, 16 include rectangularly-shaped openings 44 through which the center post extends.
  • center post 40 facilitates registration of the winding elements within the core assembly.
  • windings 12, 14 are multi-turn and require a connection of the windings at a point internal to the turns of the windings.
  • the interconnection of inner tabs 28 and 30 of windings 12 , 14 is made possible by the pre-for ed holes 24 provided within insulative sheets 22 of windings 12, 14, 16.
  • inner tabs 28, 30 project within the holes formed within its encapsulating insulative sheet and are positioned one above the other.
  • the winding turns of the metal strip conductors 12a, 14a, 16a include segments generally joined at right angles to each other.
  • the junction of these segments may be in the form of bends having a predetermined radius of curvature to improve the magnetic characteristics of the winding and to provide a more effective seal over the relatively thick metal strip.
  • each of the winding elements 12, 14, 16 are generally fabricated on a lead frame strip 48 (Fig. 10) .
  • a lead frame strip 48 Fig. 10
  • Metal strips 12a, 14a and 16a are preferably formed by a stamping or photochemical etching process (step 100) .
  • the metal strips may, alternatively, be formed with a wire electronic discharge machining (EDM) process.
  • EDM wire electronic discharge machining
  • various finishing operations may be required (step 102) .
  • a coining process may be used to remove burrs from the edges of the strips.
  • a microetching step may also be performed after coining in preparation of a plating operation.
  • the adhesively-clad insulator sheets 22 are cut into strips and are provided with holes 24 (e.g., pre-punched or pre-drilled) (step 104) .
  • the holes are about 0.100 inches in diameter and may be formed in both of the insulative sheets or simply the insulative sheet which faces the winding to which the metal strip connects.
  • the insulative sheets are positioned on both sides of the metal strip within an assembly fixture (not shown) with the adhesive backing of the sheets in contact with the metal strip.
  • metal strips 12a, 14a which correspond to the primary winding of transformer 10
  • the metal sheets are aligned with holes 24 overlying end tabs 28, 30 of the metal strips so that the tabs project into and are exposed by the holes.
  • the metal strip is then thermally bonded within the insulative sheets by applying heat and pressure to the insulative sheets using a differential pressure lamination apparatus (step 106) .
  • a differential pressure lamination apparatus provides a vacuum to eliminate any air between the insulative sheets, thereby ensuring an effective seal.
  • Conformal press pads may be used to apply the pressure to the winding structure.
  • the levels of pressure and heat applied to the insulative sheets and metal strips during the sealing process are determined empirically depending on a number of factors, including the number of units being processed at a given time. In most applications, however, the applied temperature is generally as high as 190°C and the pressure levels are as high as 500 psi. These temperature and pressure levels are applied for about 1.5 hours (at temperature).
  • Fig. 6A an exploded cross-sectional side view of the area region of holes 24 of the stacked arrangement of windings 12, 14, 16 is shown. It is important to note that in areas where a tab is not intended to extend from the insulative sheets, the sheets are cut or pre-punched to provide an insulative sheet region 50 which extends beyond the end of the metal strip which the sheets enclose. In this way, when the differential pressure lamination process is applied to the insulator sheets, the extended regions are "pursed” to provide a reliable seal of the metal strip. To ensure an effective seal between the thin insulative sheets and the thick metal strips, the length of region 50 is generally desired to be 1.5 to 2 times the thickness of the metal strip. For example, for a 40 mil thick metal strip, the length of region 50 should be between 60 and 80 mils long.
  • the exposed surfaces of the metal strip are tin-plated to prevent oxidation of the copper and to improve solderability to their surfaces (step 108).
  • the exposed surfaces include inner tabs 28, 30 which project into their respective holes 24 as well as terminals 26, 30, 32 which extend from the periphery of the winding
  • the metal strips may be plated prior to laminating the insulative sheets, it is preferable to do so afterwards.
  • Plating after laminating allows the assembler to test the quality of the seal. Any leak in the laminated insulative sheets will result in "wicking" of the plating under the sheets and onto supposedly sealed surfaces of the metal strips. The assembler can, therefore, visually inspect for a defective seal by visually inspecting for plating on surfaces of the metal strip beneath the laminated insulative sheets.
  • edges of the laminated insulative sheets 42 are generally trimmed to finish the laminated winding element (step 110) .
  • additional openings e.g. , rectangularly-shaped openings 44
  • the winding elements are positioned within a fixture (not shown) .
  • the fixture has pins which are directed from either side of the assembly and bend the tab ends 28, 30 in a direction toward each other (indicated by arrows) causing them to contact each other in a region of the pre-formed hole 44 in insulative sheet 22 of secondary winding element 16.
  • tabs 28, 30 may be formed to have a width less than their associated metal strips' 12a, 14a to facilitate their interconnection.
  • metal strip 14a of winding element 14 includes an inner tab 26a which is longer than an inner tab 30a associated with metal strip 12a of winding element 12.
  • tabs 28a and 30a are both bent in the same direction (here upward) so as to extend out of holes 24a where they are easily soldered together. This arrangement facilitates visual inspection and testing of the solder joint.
  • having tabs 28a and 30a extend out of hole 24 is better suited for applications in which the tabs are soldered using a commercial wave soldering machine or a drag soldering system.
  • holes 24a are preformed to be elongated and larger than holes 24 of Figs. 4A and 4C. Holes 24a are larger to accommodate the longer tabs of 30a which must extend through windings 12 and 16. Moreover, the larger holes may be desirable in applications where the high levels of pressure applied during the lamination of insulative sheets 22 causes the adhesive backing to be drawn into the hole, thereby shrinking its size. Moreover, because tabs 28a and 30a are connected outside the hole rather than in the region of the hole in secondary winding 16, hole 24b of secondary winding 16 may be made smaller. The smaller hole 24b allows metal strip 16a to be made slightly smaller, thereby decreasing the overall dimensions of the transformer.
  • the assembled windings are then arranged in any of variety of stacked configurations and are bonded together with an adhesive, such as a thermally curable epoxy (step 112) . It is important to note that because the windings are individually sealed (as described above in connection with step 106) this secondary bonding step need not be relied upon to provide a moisture impervious seal of the windings. Solder paste or a preform is then applied to the contacting tab ends and is melted using a reflow oven (step 114) . Alternatively, as mentioned above, the windings may be conveyed through a commercial wave soldering machine or a drag soldering system.
  • the assembled winding elements are then removed from the lead frame strips and terminals 26, 30, 32 are generally bent to allow attachment to surface mounted holes of a printed circuit board (step 116) .
  • pins or other terminal elements may be attached to the external and inner end tabs to allow connection to the printed circuit board.
  • the adhesively-bonded windings may then be assembled within a ferrite core assembly (step 118) .
  • a ferrite core assembly For example, in the transformer arrangement shown in Fig. 2, windings 12, 14 and 16 are mounted within E-core member 36 of the core assembly. Top plate 38 is then adhesively attached to E-core member thereby securing the winding elements within the core assembly.
  • center post 40 may contact the top plate, while in others, the center post is spaced by a gap 54 (Fig. 3) which is selected to control the flux density of the magnetic circuit.
  • the stacked arrangements of winding assemblies may be combined in any number of different ways to provide transformers having different characteristics.
  • the transformer 10 described above in conjunction with Figs. 1-4 is designed to have a 4:1 turns-ratio. Electrically interconnecting different combinations of this transformer may provide a transformer with different characteristics.
  • Fig. 9 for example, a cross-sectional view of a pair of transformers, each similar to that described above, are shown stacked one above the other and electrically connected together. This configuration is well suited for applications requiring increased efficiency and a lower output voltage.
  • reference numerals identifying the same elements of the transformer of Fig. 1 are used.
  • the uppermost transformer assembly 10a includes a secondary winding positioned between a pair of winding elements 12, 15 which together form the primary winding of the transformer. Winding elements 12 and 15 are electrically connected by soldering inner tabs 28, 30 at hole 44.
  • Lowermost transformer 10b is a mirror image of transformer 10a and is separated from transformer 10a by an insulative polyimide sheet 80 which serves as a barrier between transformers 10a and 10b.
  • winding 15 is identical to winding 14 of Figs. 1-4 except that external terminal element 82 extends from the center of the winding rather than along an outer edge of winding 14. Providing terminal element 82 at the center of the winding results in the terminal elements 82 overlying each other so that they can be easily interconnected by soldering.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Coils Of Transformers For General Uses (AREA)

Abstract

La présente invention concerne un assemblage planaire d'enroulements comportant un premier ensemble d'enroulements (12, 14) et un deuxième enroulement (16). Chaque enroulement possède un axe (12) et une paire de couches de feuille isolantes (22), conjointement stratifiées, dont une au moins de chacune des paires de feuilles isolantes présente un trou (24). Chaque enroulement inclut en outre un conducteur à bande métallique (12a, 14a, 16a) autour de l'axe de son enroulement et se trouve scellé entre les couches stratifiées des feuilles isolantes. Le conducteur à bande métallique comporte une partie se projetant dans le trou. Le conducteur à bande métallique du premier enroulement est relié électriquement au conducteur à bande métallique du deuxième enroulement par les trous des feuilles isolantes.
PCT/US1997/013752 1996-08-05 1997-08-05 Transformateur planaire WO1998006112A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP97938117A EP0919062A4 (fr) 1996-08-05 1997-08-05 Transformateur planaire

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/693,878 US5781093A (en) 1996-08-05 1996-08-05 Planar transformer
US08/693,878 1996-08-05

Publications (1)

Publication Number Publication Date
WO1998006112A1 true WO1998006112A1 (fr) 1998-02-12

Family

ID=24786492

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1997/013752 WO1998006112A1 (fr) 1996-08-05 1997-08-05 Transformateur planaire

Country Status (5)

Country Link
US (2) US5781093A (fr)
EP (1) EP0919062A4 (fr)
KR (1) KR20000029817A (fr)
CN (1) CN1232572A (fr)
WO (1) WO1998006112A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
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WO1999031682A3 (fr) * 1997-12-17 1999-08-19 Koninkl Philips Electronics Nv Transformateur plan
WO2000011687A1 (fr) * 1998-08-21 2000-03-02 Nucleus Ecopower Limited Transformateur plan
US9620278B2 (en) 2014-02-19 2017-04-11 General Electric Company System and method for reducing partial discharge in high voltage planar transformers

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US5781093A (en) 1998-07-14
CN1232572A (zh) 1999-10-20
US5949321A (en) 1999-09-07
EP0919062A1 (fr) 1999-06-02
EP0919062A4 (fr) 2000-03-15
KR20000029817A (ko) 2000-05-25

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